Knitted tensile structures

ABSTRACT

A knit component may include a knit-in tensile area, which may include an opening at least partially bounded by a first intersecting portion and a second intersecting portion. A course of tensile material that is integrally knitted with the first intersecting portion via a knit stitch may include a float extending from the first intersecting portion, across the opening, to the second intersecting portion. A knitting method may knit courses of the knit component on needle beds and then widen and/or narrow parts of the opening by transferring stitches of one of the courses of the knit component to different needles.

CROSS-REFERENCE TO RELATED APPLICATION(S)

This patent application is a divisional of and claims the benefit ofU.S. Non-Provisional patent application Ser. No. 16/251,659, entitled“Knitted Tensile Structures” and filed on Jan. 18, 2019, the entirety ofwhich is incorporated herein by reference. Note that U.S.Non-Provisional patent application Ser. No. 16/251,659 claims thebenefit of U.S. Provisional Patent Application No. 62/619,269, filedJan. 19, 2018, the entirety of which is incorporated therein byreference.

BACKGROUND

The present embodiments relate generally to knit components and methodsof manufacturing knit components, for example, knit components for usein apparel and footwear applications.

SUMMARY

A knit component may include a knit-in tensile area, which may includean opening at least partially bounded by a first intersecting portionand a second intersecting portion. A course of tensile material that isintegrally knitted with the first intersecting portion via a knit stitchmay include a float having a float length extending from the firstintersecting portion, across the opening, to the second intersectingportion. The float length may be at least three needles long. The courseof tensile material may have a diameter of at least 0.8 mm and a tensilestrength of at least 25 kg-f, and may be integrally knitted with thesecond intersecting portion via a second knit stitch. The knit componentmay further include a second course of tensile material that isintegrally knitted with the first intersecting portion, and the secondcourse of tensile material may include a second float extending from thefirst intersecting portion, across the opening, to the secondintersecting portion. A course of tensile material may include a secondfloat having a second float length. The opening may have a shapeconsisting of a triangle, a square, a rectangle, a pentagon, an ellipse,or a circle. The first intersecting portion may conceal the knit stitchof the course of tensile material from a viewing angle facing a firstsurface of the first intersecting portion.

In another aspect, an upper may include a first knit-in tensile areathat includes a course of tensile material extending across a pluralityof openings, each opening being at least partially bounded by aplurality of intersecting portions and a plurality of arterial portions.The course of tensile material may be integrally knit with eachintersecting portion of the plurality via one or more knit stitches andmay include a plurality of floats (each having a float length) that eachextend across one opening of the plurality of openings. The course oftensile material may have a medial-lateral orientation, and may extendfrom a lateral edge region to a medial edge region. The course of thetensile material may extend in a weft direction of the knit-in tensilearea. The upper may also include a second knit-in tensile areacomprising a second plurality of openings and a second course of tensilematerial, and the second knit-in tensile area may be located in adifferent region of the upper from the first knit-in tensile area. Thefirst knit-in tensile area may be located in a midfoot region and thesecond knit-in tensile area may be located in a rearfoot region. Thesecond course of tensile material may have a different orientation thanthe course of tensile material. Each of the plurality of openings mayhave a first shape and a first size, and each of the second plurality ofopenings may have a second shape and a second size.

In another aspect, a knitting method may include knitting a first courseof a multi-bed knit structure on a first needle bed and a second needlebed, transferring a first plurality of stitches of the first course ofthe multi-bed knit structure to different needles to widen an opening,knitting a course of tensile material, including at least one stitchthat interloops with the multi-bed knit structure and a float that spansthe opening, knitting a second course of the multi-bed knit structure onthe first and second needle beds, and transferring a second plurality ofstitches of the second course of the multi-bed knit structure todifferent needles to narrow the opening. The float may have a floatlength of at least three needles, and the multi-bed knit structure mayhave a tubular knit structure.

Other systems, methods, features and advantages of the presentdisclosure will be, or will become, apparent to one with skill in theart upon examination of the following figures and detailed description.It is intended that all such additional systems, methods, features andadvantages be within the scope of the present disclosure, and beencompassed by the following claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure can be better understood with reference to thefollowing drawings and description. The components in the figures arenot necessarily to scale, emphasis instead being placed uponillustrating the principles of the present disclosure. Moreover, in thefigures, like referenced numerals designate corresponding partsthroughout the different views.

FIG. 1 is a sectional view of a knit component in accordance with oneaspect of the present disclosure.

FIG. 2 is an expanded sectional view that shows another aspect of theknit component of FIG. 1.

FIG. 3 is a cross-sectional view that shows another aspect of the knitcomponent of FIG. 1.

FIG. 4 is a sectional view of another knit component in accordance withanother aspect of the present disclosure.

FIG. 5 is an expanded sectional view that shows another knit componentin accordance with another aspect of the present disclosure.

FIG. 6 is a sectional view of an upper in accordance with one aspect ofthe present disclosure.

FIG. 7 is a perspective view of an article of footwear in accordancewith one aspect of the present disclosure.

FIG. 8 is a knit diagram in accordance with one aspect of the presentdisclosure.

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring to FIGS. 1-3, a knit component 10 suitable for a number ofapplications, e.g., footwear and apparel, may be formed as an integralone-piece element from a single knitting process, such as a weftknitting process (e.g., with a flat knitting machine with one, two, ormore needle beds, or with a circular knitting machine), a warp knittingprocess, or any other suitable knitting process. Knit component 10 mayhave integral knit construction in that it may be formed by a knittingprocess without the need for significant post-knitting processes orsteps. Alternatively, two or more portions of knit component 10 may beformed separately as distinct integral one-piece elements, and then therespective elements may be attached. In all of the aforementioned cases,the resulting knit component may be formed via integral knitconstruction.

Knit component 10 may include at least a first layer 12 and a secondlayer 14. The first layer 12 and second layer 14 may be formed on one ormore needle beds of a knitting machine, e.g., a first needle bed and/ora second needle bed. When the first layer 12 is formed on a differentneedle bed than the second layer 14, or when either of the first orsecond layers 12, 14 are formed on more than one needle bed, theresulting knit component 10 has multi-bed knit construction. As used inthis application, the first layer 12 may form a first surface 16comprising a first plurality of knit loops, and the second layer 14 mayform a second surface 18 comprising a second plurality of knit loops.The first layer 12 may overlap at least a portion of the second layer14, and the first and second layers 12, 14 may be coterminous in one ormore dimensions but need not be coterminous. In some areas, the firstlayer 12 may be freely separable from the second layer 14. In otherwords, the first layer 12 and second layer 14 may have opposite facinginternal surfaces. Although the first layer 12 may be freely separablefrom the second layer 14 in certain areas, it need not be freelyseparable. For example, knit component 10 may include one or moreinterlayer knit stitches that join the first and second layers 12, 14(e.g., stitches formed between a first needle bed and a second needlebed on a weft knitting machine). Such interlayer knit stitches may beformed by the same yarn(s) that forms the first and/or second layers 12,14, or a different yarn (such as a tensile material, discussed below). Asingle course of material may form both the first layer 12 and secondlayer 14, e.g., a knit structure formed on both a first and secondneedle bed that includes a first plurality of knit loops on a surface ofthe first layer 12 and a second plurality of loops on a surface of thesecond layer 14. Alternatively, different courses of material may formthe first and second layers 12, 14, e.g., a first course forming asingle jersey layer on a first needle bed and a second course forminganother single jersey layer on a second needle bed.

Knit component 10 may include additional layers, e.g., to addcushioning, protection, or for other advantage. In various applications,the first layer 12 or second layer 14 may correspond with an outer orinner layer of an article of apparel, and exterior or interior layer ofan upper for an article of footwear, or other application.

First and second layers 12, 14 may be knitted from the same or differentmaterials, and may each be knitted from one or more materials, dependingupon the application. For example, the first layer 12 may be knittedpartially or completely from a material selected for durability, e.g., amaterial with relatively high abrasion resistance and tenacity. Asanother example, the second layer 14 may be knitted from a materialselected for soft hand.

Still referring to FIGS. 1-3, the knit component 10 may include one ormore knit-in tensile areas 20, which may be located where it isdesirable to limit stretch, to improve ventilation, to permit visibilitythrough knit component 10, and/or to provide additional technicalproperties. For example, knit component 10 may be incorporated into anarticle of footwear, and knit-in tensile area 20 may be positioned in alocation where it is desirable to limit the movement of a wearer's footin a medial and/or lateral direction. As another example, knit component10 may be incorporated into a shirt, a pair of pants, or other garment,and knit-in tensile area 20 may be positioned where it is desirable toimprove ventilation. As yet another example, knit component 10 may beincorporated into an industrial textile, and knit-in tensile area 20 maybe positioned where it is desirable to have relatively high strength,minimal stretch, and relatively high permeability.

The knit-in tensile area 20 may include portions of the first layer 12and the second layer 14, and also includes one or more courses oftensile material 22 that are integrally knitted into the first and/orsecond layers 12, 14. Suitable tensile materials include yarns formedwith low-stretch/low-elasticity materials with relatively high tensilestrength (e.g., at least approximately 25 kg-f) and high tenacity, e.g.,cables, strands, and cords with a diameter of at least 0.5 mm (e.g., 0.8mm or 0.5 mm-2.0 mm). Other suitable tensile materials may includestrands or fibers having a low modulus of elasticity as well as a hightensile strength, such as strands of monofilament material, or fiberssuch as SPECTRA™ fibers, manufactured by Honeywell International Inc.(Morris Township, N.J.). Other suitable tensile materials may includevarious filaments, fibers, and yarns, formed from rayon, nylon,polyester, polyacrylic, silk, cotton, carbon, glass, aramids (e.g.,para-aramid fibers and meta-aramid fibers), ultra-high molecular weightpolyethylene, and liquid crystal polymer. As one non-limiting example,the tensile material may be a 1.0 mm diameter sheathed polyester cablehaving a minimum tensile strength of 30 kg-f and a maximum elongation ofless than approximately 50%. The selection of the tensile material maybe further influenced by knitting machine considerations. For example,the tensile material may have a sufficiently small diameter to permitperiodic interlooping with the first and/or second layers 12, 14 withoutdamaging the knitting machine, e.g., interlooping every third, fourth,fifth, sixth, seventh, eighth, or greater needle on a needle bed.Generally, the tensile material may have the same or different visualproperties as other material that form the knit component. By utilizinga tensile material with at least one different visual property (e.g., acontrasting color or texture), the knit component may provide anattractive appearance.

Each course of tensile material 22 may include a single yarn or strand,or may include a plurality of yarns or strands of tensile material. Forexample, course of tensile material 22 may include a single 1.0 mmdiameter sheathed polyester cable, or alternatively may include aplurality of smaller diameter strands of tensile material, e.g., eachhaving a different color for visual effect or each having a differentmaterial composition.

Referring still to FIGS. 1-3, knit-in tensile area 20 may include one ormore tensile structures 24, each of which may include a plurality ofintersecting portions 26 a-d and a plurality of arterial portions 28 a-dthat surround an opening 30. Each tensile structure 24 also includes atleast one course of tensile material 22 that extends across opening 30and is interlooped with at least one of intersecting portions 26 a-d.Each intersecting portion 26 a-d exists at a nexus of arterial portions28 a-d. Opening 30 may extend through knit component 10. Course oftensile material 22 includes a float 32 that spans opening 30 betweenadjacent intersecting portions 26 b, 26 d. In other embodiments, thefloat of tensile material need not span the opening across its largestdimension, and in other embodiments, a plurality of courses of tensilematerial may span the opening.

Course of tensile material 22 is integrally knitted into knit component10, e.g., interlooped with at least one of intersecting portions 26 a-dby one or more knit stitches as a result of the knitting process. Theinterlooping of course of tensile material 22 may be contrasted with aninlaying process that does not interloop the inlaid course with knitcomponent. Integrally knitting course of tensile material 22 into knitcomponent 10 advantageously secures it within knit component 10;otherwise, course of tensile material 22 could translate in thecourse-wise direction relative to knit component 10, e.g., due to atensile force. In knit component 10 however, course of tensile material22 may include a first stitch 34 that is interlooped with intersectingportion 26 b, and an optional second stitch 36 that is interlooped withintersecting portion 26 d. In other embodiments, course of tensilematerial 22 may include additional stitches that interloop with eachintersecting portion. For example, in other embodiments, each course oftensile material may include two, three, or a greater number of stitchesthat interloop with each intersecting portion. As another example, inother embodiments, each course of tensile material may interloop withevery other intersecting portion through which it passes. Generally, acourse of tensile material may be integrally knitted with any aspect ofan intersecting portion, e.g., portions of the first and/or the secondlayer that form the intersecting portion. Depending on how courses oftensile material are integrally knitted into the knit component,intersecting portions may conceal one or more stitches of course oftensile material from one or more viewpoints. For example, in theembodiment of FIGS. 1-3, first stitch 34 of course 22 is knitted intofirst layer 12; therefore first stitch 34 may be substantially orcompletely concealed from a viewpoint from which second layer 14 isvisible. By comparison, stitch 38 is knitted into second layer 14, andtherefore may substantially concealed from another viewpoint from whichfirst layer 12 is visible.

Referring still to FIGS. 1-3, course of tensile material 22 includesfloat 32 that spans opening 30. Generally, each course of tensilematerial may include one or more floats that span one or more openings.Advantageously, float 32 may contribute to stretch resistance in thedirection of the course of tensile material 22, and may also preventpassage of objects through opening 30 while preserving breathability ofknit component 10. Float 32 is straight across opening 30 (e.g., taut);although in other embodiments (such as in FIG. 5), floats may not bestraight (e.g., may have slack). Generally, a straight float mayincrease stretch resistance of the knit component because it limitsmechanical stretch (as compared to a knit stitch or a float with slack,which may allow mechanical stretch, i.e., straightening of the coursedue to application of a tensile force). The distance along a floatbetween stitches adjacent may define the float length, which maycoincide with the distance along a float between adjacent intersectingportions. For example, in FIGS. 1-2, float 32 has a float length equalto the distance along float 32 between the first and second stitches 34,36, which approximately coincides with the distance along float 32between intersecting portions 26 b, d.

Given its potentially higher stiffness and larger diameter relative toother materials that may form the knit component, the tensile materialmay be relatively difficult to knit on a knitting machine as compared toother materials. For example the course of tensile material 22 may bemore difficult to knit than materials used to form first and secondlayers 12, 14. To alleviate these challenges and to facilitate knittingthe tensile material, the float length of each course of tensilematerial may range from a small number of floated needles, e.g., two tothree needles, up to a larger number of floated needles, e.g., five toten needles. In embodiments such as FIGS. 1-3 where each course oftensile material (such as course 22) includes a plurality of floats(i.e., where the same course of tensile material extends across morethan one opening), each float may have the same or different floatlength, e.g., to tailor the stretch resistance of the knit-in tensilearea at particular location along the course of tensile material.

In some embodiments, a second float (e.g., a float of non-tensilematerial forming part of the first or second layers, or a float oftensile material) may also be integrally knitted with one or moreintersecting portions and span the opening. From some viewpoints, thefloat of tensile material may obscure the second float of non-tensilematerial. The second float may further contribute to stretch resistanceof the knit component. In other embodiments (as in FIG. 4), a pluralityof courses of tensile material may span each opening between adjacentintersecting portions, and one or more of the plurality of courses oftensile material may be knitted into one or both of the adjacentintersecting portions. Additional courses of tensile material maycontribute to greater stretch resistance.

In the embodiments of FIGS. 1-3, arterial portions 28 a-d connectadjacent intersecting portions 26 a-d. Each arterial portion 28 a-dgenerally has an elongate shape, although the length of each arterialportion 28 a-d may vary significantly between embodiments and withinembodiments. For example, arterial portions 28 a-d of FIG. 2 have arelatively short length, as intersecting portions 26 a-d are relativelylarge. In other embodiments, the length of arterial portions may vary,even within the same embodiment. For example, a knit component mayinclude a first knit-in tensile area including arterial portions with arelatively short first length, and a second knit-in tensile areaincluding arterial portions with a longer second length. As the arterialportion length increases, the size of the openings in the knit-intensile area tends to increase also, contributing to greaterbreathability and visibility through the knit component. Otherembodiments may include arterial portions with more than one length.

Generally, arterial portions may intersect each other at a wide range ofangles. For example, in FIGS. 1-2, arterial portions 28 f, g may form aninterior angle of approximately one hundred degrees, while arterialportions 28 e, f form an interior angle of approximately forty degrees.In other embodiments, intersecting portions may form an angle rangingfrom approximately 30 degrees to up to approximately one hundred fiftydegrees, e.g., 40, 50, 60, 70, 110, 120, or 130 degrees. Referring stillto FIGS. 1-3, each arterial portion 28 a-d may include yarns of firstand second layers 12, 14 formed into knit loops. In other embodiments,arterial portions may not appear to include knit loops, but rathertaught yarns due to tensile forces imparted by the knitting process.Although arterial portions 28 a-d of FIGS. 1-3 are free of tensilematerial, in other embodiments, arterial portions may include one ormore integrally-knitted courses of tensile material.

Referring still to FIGS. 1-3, each intersecting portion 26 a-d mayinclude yarns of the first and second layers 12, 14, and may havemulti-bed knit construction. In each intersecting portion 26 a-d, thefirst layer 12 may be predominantly visible from a first viewpoint 41,and the second layer 14 may be predominantly visible from a secondviewpoint 42. Intersecting portions 26 b, d substantially concealstitches 34, 36 of tensile material from second viewpoint 42 (from whichthe second layer 14 is visible) because stitches 34, 36 are knitted intofirst layer 12. However, intersecting portion 26 c substantiallyconceals stitch 38 from first viewpoint 41 (from which the first layer12 is visible).

The appearance, dimensions, and structures of each intersecting portionmay vary. In the embodiment of FIGS. 1-3, each intersecting portion(e.g., 26 a-d) may have an elongate, web-like structure with a width, w,that exceeds a height, h, and a thickness, t, that approximates orexceeds the diameter of arterial portions 28 a-d. Generally, height, hmay increase with the number of courses of first and second layerscontained within each intersecting portion. For example intersectingportions may include four to ten total courses of the first and secondlayers, e.g., eight courses. In the embodiment of FIGS. 1-3,intersecting portions 26 b, d each includes eight courses: fourdouble-bed courses of each of the first and second layers 12, 14,although courses of the first layer 12 are predominantly visible inFIGS. 1-2. Generally, the width, w, may increase with the number ofwales of the first and second layers contained within intersectingportion. For example, an intersecting portion may include two to tenwales of the first and or second layers, e.g., four wales. In FIGS. 1-2,intersecting portions 26 b, d each include four wales. Generally,thickness, t, of intersecting portion may approximate or exceed thediameter of arterial portions as a result from the interlooping of atleast one course of tensile material with the first and/or second layerswithin each intersecting portion, as shown in FIG. 3. Loft inherent tothe materials and structures forming the intersecting portions may alsocontribute to increased thickness relative to arterial portions.

Generally, the intersecting portions and arterial portions surroundcircular, oblong, or elliptical openings. Referring to FIGS. 1-3,opening 30 has an approximately square or pentagonal shape that isbounded by intersecting portions 26 a-d and arterial portions 28 a-d.Second opening 44 of FIGS. 1-2 has a roughly triangular shape, but inother embodiments, the openings may have a roughly circular, elliptical,oblong, square, rectangular, hexagonal, or other shape depending uponthe dimensions of the intersecting portions and arterial portions. Inother embodiments, an opening may have a first size (i.e., area) and maybe bounded by three intersecting portions and three arterial portions.In still other embodiments, an opening may be bounded by a greaternumber of intersecting portions and arterial portions, e.g., five, six,or greater number. In other embodiments, a plurality of openings withina knit-in tensile area may have the same or different shapes and sizes.

Referring now to FIG. 4, another knit component 46 is shown thatincludes a knit in tensile area 48, which is formed from a plurality offirst tensile structures. Exemplary first tensile structure 50 includesintersecting portions 52 a-d and arterial portions 54 a-d, whichsurround a square-shaped opening 56. A course of tensile material 58spans opening 56 and interloops with intersecting portions 52 b, d. Eachintersecting portion 52 a-d may have a knot-like structure with a heightthat is similar to its width, either or both of which may exceed thediameter of arterial portions 50 a-d. That is, intersecting portions 52a-d may appear as a knot-like mass of yarns compared to relativelyslender arterial portions 54 a-d. Course of tensile material 58 includesa float 60 that spans opening 56 between intersecting portions 52 b, d.Knit in tensile area 48 also includes a plurality of second tensilestructures 61, which are similar to the first tensile structures 50except that at least two courses of tensile material (e.g., courses 62,63) span each opening. In other tensile structures of knit component 46,at least one course of non-tensile material (e.g., course 64) may spanthe opening, e.g., for the advantage of greater stretch resistance inthe course-wise direction.

In FIG. 5 an alternative knit-in tensile area 65 is illustrated thatincluding a plurality of first tensile structures (that are similar totensile structures 50 shown in FIG. 4), in addition to a plurality ofsecond tensile structures 66 that each include a non-strait float (e.g.,float 67, which may have slack or a U-shaped appearance) andintersecting portions 68 a-c having a greater height and width relativeto other intersecting portions (e.g., intersecting portion 69). However,intersecting portions 68 a-c and 69 are similar in construction and inthe fact that each intersecting portion may interloop with one or morecourses of tensile material.

The foregoing knit components are merely exemplary and not intended tolimit the scope of the present disclosure. Rather, other knit componentsof the present disclosure may include knit in tensile areas havingdifferent characteristics, including intersecting portions and openingswith different shapes and sizes, arterial portions with multiple anddifferent lengths, greater numbers of courses of tensile materialspanning each opening, knit in tensile areas with different orientationsrelative to other knit in tensile areas, etc.

Knit components constructed with knit-in tensile areas according to theabove structures may advantageously benefit from high stretch resistancein the direction parallel to the orientation of courses of tensilematerial. This stretch resistance is heightened by knitting the one ormore courses of tensile material into at least one intersecting portion,as opposed to inlaying the courses of tensile material through theintersecting portions. Moreover, the float portions of the tensilematerial may further increase stretch resistance of the knit componentby limiting mechanical stretch in the knit-in tensile area.Additionally, the knit component may also have high stretch resistancein the directions parallel to the arterial portions, which generally mayextend straight between adjacent intersecting portions (e.g., may betaut between adjacent intersecting portions). Further, the knitcomponent may have relatively high strength and resistance to tearing,owing to the intersecting portions which may secure the relativepositions of intersecting arterial portions. As yet another advantage,the knit component may advantageously provide relatively high visibilityand permeability due to the one or more openings formed in the knit-intensile area. Additional advantages will be apparent to those skilled inthe art.

Referring now to FIG. 6, an upper 70 for an article of footwear mayinclude a knit component 72 having one or more knit-in tensile areas,especially where it is desirable to limit stretch, improve ventilation,or improve visibility through knit component 72. Each knit-in tensilearea may include one or more tensile structures as described above.Upper 70 resembles a U-shape, however, it shall be understood that the“horseshoe-shape” or “U-shape” shape is merely exemplary, and otheruppers embodying the disclosure of this application may be knitted withedges in different locations, for example a “C-shaped” uppers or amultiple-piece uppers. Knit component 72 includes a first layer 74 and asecond layer (not shown). For reference purposes, upper 70 may bedivided generally along a longitudinal direction (heel-to-toe) intothree general regions: a forefoot region 78 having a forefoot edgeregion 79, a midfoot region 80, and a rearfoot region 82. Forefootregion 78 may generally include portions of upper 70 that may eventuallycover (when incorporated into an article of footwear) the toes and thejoints connecting the metatarsals with the phalanges. The midfoot region80 may generally include portions corresponding with an arch area of thefoot, and may include a throat region 81. The rearfoot region 82 maygenerally correspond with rear portions of the foot, including areasthat cover the calcaneus bone (which comprises a portion of a wearer'sheel). Additionally, the rearfoot region 82 may cover some or all of thewearer's malleoli and talus (which comprise a portion of the ankle). Therearfoot region 82 may coincide with a collar region 83. Upper 70 mayalso include a medial side 84 having a medial edge 86 and a medial edgeregion 88, and a lateral side 90 having a lateral edge 92 and a lateraledge region 94. Each of the medial and lateral sides 84, 90 may extendthrough each of the forefoot region 78, midfoot region 80, and rearfootregion 82, and may correspond with opposite sides. More particularly,lateral side 90 may correspond with an outside area of the foot (i.e.,the surface that faces away from the other foot), and medial side 84 maycorrespond with an inside area of the foot (i.e., the surface that facestoward the other foot). The forefoot region 78, midfoot region 80,rearfoot region 82, medial side 84, and lateral side 90 are not intendedto demarcate precise areas of upper 70 or knit component 72, but ratherare intended to represent general areas to aid in the followingdiscussion.

Referring still to FIG. 6, first layer 74 may eventually correspond withan exterior layer and the second layer may eventually correspond with aninner layer. Upper 70 also includes first knit-in tensile area 96located in rearfoot region 82, a second knit-in tensile area 100 locatedin midfoot region 80, and a third knit-in tensile area 102 located inforefoot region 78. It shall be understood that knit structures presentin any region of upper 70 may also be suitable in any other region ofany upper.

First knit-in tensile area 96 is located on medial side 84 of knitcomponent 72 and extends from collar region 83 to medial edge region 88.Courses of tensile material (e.g., course 106) extend from a rear edgeregion to midfoot region 80. Courses of first knit-in tensile area 96may have a different orientation than courses of other knit-in tensileareas due to the use of gores or wedges (e.g., wedge 108) in the knitcomponent 72. Generally, gores or wedges may be utilized to adjust theorientation of any knit-in tensile area.

First knit-in tensile area 96 may have similar knit structures (e.g.,tensile structure 104) constructed as described above, with each tensilestructure 104 including at least one portion of a course of tensilematerial (e.g., course 106) that is oriented in a longitudinal direction(which may correspond with a weft direction and a forefoot-rearfootorientation) with a float that spans an opening (e.g., opening 107,which has a first float length). Arterial portions (such as arterialportion 109) extend from collar region 83, diagonally downward towardmedial edge region 88. Other arterial portions extend diagonally upward.When incorporated into an article of footwear, first knit-in tensilearea 96 may secure upper 70 around the rear of a wearer's foot bypreventing longitudinal stretch. As first knit-in tensile area 96 mayexperience relatively low tensile forces as compared to other knit-intensile areas, materials selected for these areas may differ from otherknit-in tensile areas. For example, first knit-in tensile area 96 mayinclude tensile material with a lower maximum tensile strength thantensile material utilized in other knit-in tensile areas. Similarly, dueto relatively high abrasive forces that may be experienced in rearfootregion 82, materials utilized for first layer 74 may differ from othermaterials utilized elsewhere in knit component 72.

Second knit-in tensile area 100, located in midfoot region 80, includesa plurality of first tensile structures (e.g., structure 110 with afloat having a second float length) and second tensile structures (e.g.,structure 112 with a strait float having a third float length), bothconstructed as described above. Second knit-in tensile area 100 includesone or more courses of tensile material (e.g., course 113) extendingfrom medial edge region 88 (including medial edge 86) to lateral edgeregion 94 (including lateral edge 92), and may also include one or morepartial courses of tensile material (e.g., course 114) that extend fromthroat region 81 to lateral edge region 94 (including lateral edge 92)or medial edge region 88 (including medial edge 86). This medial-lateralorientation may correspond with a weft direction. Courses of tensilematerial may extend beyond medial and lateral edges 86, 92, e.g., tofacilitate securing those courses to other structure, such as a solestructure, for the advantage of increased stretch resistance andstrength. This medial-lateral configuration of tensile material inmidfoot region 80 may advantageously contribute to a high degree of“lock down” or medial-lateral stability when upper 70 is incorporatedinto an article of footwear. In other embodiments, courses of tensilematerial in midfoot region 80 need not have a strictly medial-lateralorientation, but may extend diagonally (e.g., upward and forward) or mayhave another orientation. Given that midfoot region 80 will likelyexperience relatively high tensile forces, materials utilized in thirdknit-in tensile area 100 may differ from other materials used in knitcomponent 72. For example, tensile material utilized in third knit-intensile area 100 may have greater maximum tensile strength than tensilematerials utilized in other knit-in tensile areas.

Third knit-in tensile area 102, located in forefoot region 78, includesa plurality of first tensile structures 116 and a plurality of secondtensile structures 118. First tensile structures 116 may be spaced apartby one or more openings 120 that are free of tensile material. Spacingapart tensile structures may advantageously save weight and materialscosts while increasing breathability and visibility through knitcomponent 72. Second tensile structures 118 may each include more thanone float of tensile material spanning each opening, e.g., for increasedstretch resistance. Each course of tensile material extends from medialedge region 88 (including medial edge 86) to lateral edge region 94(including lateral edge 92), while third knit-in tensile area 102extends from forefoot edge region 79 to midfoot region 80.

The foregoing knit-in tensile structures are exemplary and not intendedto limit the scope of the present disclosure. Rather, other knit-intensile structures in other embodiments may utilize one or more featuresof any of the foregoing examples, and may have additional differences.For example, a knit component may include first and second knit-intensile areas. Floats in the first knit-in tensile area may have a firstfloat length and the openings may have a first shape (e.g., square,circular, elliptical, triangular, etc.) and a first size, whereas floatsin the second knit-in tensile area may have a second float length thatis the same or different from the first float length. Likewise, openingsin the second knit-in tensile area may have openings with the same ordifferent shapes and sizes as the first knit-in tensile area. In thesame or other embodiments, along each course of tensile material, thefloat length of different floats may differ.

In FIG. 7 an article of footwear 122 is shown that includes an upper 124at least partially formed with a knit component 126. Article 122 has ageneral configuration suitable for walking or running. Conceptsassociated with footwear, including upper 124 and knit component 126,may also be applied to a variety of other athletic footwear types,including but not limited to baseball shoes, basketball shoes,cross-training shoes, cycling shoes, football shoes, soccer shoes,sprinting shoes, tennis shoes, and hiking boots. The concepts may alsobe applied to footwear types that are generally considered to benon-athletic, including dress shoes, loafers, sandals, and work boots.The concepts disclosed herein apply, therefore, to a wide variety offootwear types. In the embodiment of FIG. 7, upper 124 may generallyprovide a comfortable and secure covering for a wearer's foot. As such,upper 124 may define a void 128 to effectively receive and secure a footwithin article 122. Moreover, an optional sole structure 130 may besecured to a lower area of upper 124 and may extend between a wearer'sfoot and the ground to attenuate ground reaction forces (i.e., cushionthe foot), provide traction, enhance stability, and influence themotions of the foot.

Article 122 may include one or more knit-in tensile areas, utilizingaspects from any of the knit component and upper examples describedabove. For example, knit component 126 of article 122 includes a firstknit-in tensile area 132 positioned on a lateral side 134, and may alsoinclude a second knit-in tensile area positioned on a medial side (notshown). Courses of tensile material (e.g., course 135) may extend acrossan overfoot portion 136 of article 122, e.g., from a lateral edge region138 (including lateral edge 140) to a medial edge region (including amedial edge). Additionally or alternatively, courses of tensile material(e.g., course 142) may extend partially over article 122, e.g., fromlateral edge region 138 to a throat region 144. One or more courses oftensile material may be secured to sole structure 130, e.g., at lateraledge region 138, such as with adhesives or other joining methods.Securing one or more courses of tensile material to sole structure 130may advantageously improve the media-lateral stability of article 122 bypreventing movement of a wearer's foot within void 128. Courses oftensile material may also cooperate with a fastening system 146. Forexample, a lace may traverse an opening of a tensile structure, i.e.,utilize the opening as a lace loop. Alternatively, fastening system 146may attach to knit-in tensile area 132, e.g., for the benefit ofproviding a secure anchor point.

Referring now to FIG. 8 a knitting sequence is illustrated that may beutilized to form integrally-knit components as described above, such asthrough a weft knitting process (e.g., with a flat knitting machine withone, two, or more needle beds). The non-limiting sequence of FIG. 8 isillustrated on a weft knitting machine having a first needle bed 150 anda second needle bed 152. The knitting sequence illustrates the formationof a knit-in tensile area that utilizes courses of a tensile material154, along with courses of a first material 156 and a second material158 to form a first and a second layer.

At a first step 160, the knitting machine forms a course 162 of tensilematerial 154 by periodically knitting stitches on second needle bed 152,separated by floats. Each stitch may be knitted into an intersectingportion, and each float may span an opening formed in previous knittingsteps (not shown). The floats each skip a number of needles between knitstitches, e.g., two to ten needles. In other words, the floats may havea float length of at least two needles. In FIG. 8, for example, thefloats formed during course 162 each skip five needles. In otherembodiments, the float length may be longer or shorter, for example,depending upon the properties of the tensile material (e.g., diameterand stiffness) that influence how easily it knits on the knittingmachine, or depending upon whether the float will be straight or not(e.g., whether it is taut or slack), or depending upon the size of theopenings in the knit component. In still other embodiments, a singlecourse of tensile material may include floats having more than one floatlength. In first step 160, the knitting machine fixes the position ofcourse 162 within the knit component by interlooping with one or morepreviously-knitted courses, and prepares course 162 to interloop withintersecting portions of the knit component in subsequent steps. Infirst step 160, all stitches of course 162 (of tensile material 154) areformed on second needle bed 152, where they will interloop with stitchesof the second layer in subsequent steps. Alternatively, stitches ofcourses of tensile material may be formed entirely or in part on firstneedle bed 150 to prepare for subsequent interlooping with stitches ofthe first layer. By forming all stitches of course 162 on a singleneedle bed, the finished knit component may conceal those stitches fromat least one viewpoint. For example, by knitting loops of course 162 onsecond needle bed 152 where those stitches will interloop with one ormore courses of the second layer, those stitches of course 162 may beconcealed from a first viewpoint where the first layer is visible.

At a second step 164, the knitting machine closes course 162 of tensilematerial 154 knitted at first step 160 by knitting courses of first andsecond materials 156, 158, respectively. For example, in FIG. 8, courses166, 168 form an interlock knit structure of first and second materials156, 158. Both of courses 166, 168 include stitches formed on both thefirst and second needle beds 150, 152. In this step, at least one ofcourses 166, 168 interloops with stitches of course 162 of tensilematerial 154 knitted during first step 160. For example, in FIG. 8,course 168 of second material 158 interloops with each loop of course162 of tensile material 154. However, in other embodiments, the firstand/or second layers need not interloop with all loops of the tensilematerial.

Following first and second steps 162, 164 the knitting machine will haveknitted one or more intersecting portions at each location where theinterlocking courses of first and second materials 156, 158 interloopwith knit stitches of tensile material 154. Additionally, the knittingmachine will have knitted one or more floats of tensile material 154across openings formed by previous knitting steps (not shown).

At a third step 170, the knitting machine begins to form intersectingportions, openings, and arterial portions in the knit component byalternating between knitting additional courses of first and secondmaterials 156, 158 and by executing inter-needle transfers of stitchesof those courses. In FIG. 8, course 172 of first material 156 and course174 of second material 158 form a multi-bed knit structure thatinitially does not form part of an opening. For example, courses 172,174 may form a tubular knit structure. Subsequently however, theknitting machine executes transfer steps 176, 178 that move knitstitches of courses 172, 174 to other needles. The locations of thesetransfers coincide with floats of tensile material 154 that will beknitted in subsequent steps. More specifically, transfer steps 176, 178pull stitches of courses 172, 174 apart from each other, therebycreating openings and forming arterial portions of the knit componentaround the openings. Following transfer steps 176, 178, the knittingmachine knits optional courses 180-186 and executes additional transfersteps 188, 190 to further widen the openings and lengthen arterialportions. In other embodiments having smaller openings and shorterarterial portions, courses 180-186 and transfers 188, 190 may not benecessary. Likewise, in other embodiments having larger openings andlonger arterial portions, third step 170 may include additional coursesand transfers. Following first through third steps 160, 164, 170, theknitting machine will have knitted one or more intersecting portions andone or more partial openings in the knit component.

At a fourth step 192, the knitting machine knits another course 194 oftensile material 154 by periodically knitting stitches on second needlebed 152, separated by floats that span the partial openings formedduring third step 170. Where course 194 of tensile material 154 formsstitches on second needle bed 152, it forms part of additionalintersecting portions of the knit component.

At a fifth step 196, the knitting machine completes the openings startedin third step 170 by alternating between knitting additional courses offirst and second materials 156, 158 and executing additionalinter-needle transfers. In FIG. 8, courses 198, 202 of first material156 and courses 200, 204 of second material 158 form a multi-bed knitstructure (e.g., tubular knit), similar to third step 170. Subsequently,the knitting machine executes transfer steps 206, 208 that move knitstitches of courses 198-204 to other needles. Unlike third step 170,when transfers pulled stitches apart (making the openings larger),transfer steps 206, 208 of fifth step 196 pull stitches together (makingthe openings smaller). In other words, third step 170 forms the wideningpart of the openings, whereas fifth step 196 forms the narrowing part ofthe openings. More specifically, transfer steps 206, 208 pullspaced-apart stitches of courses 198-204 toward each other, therebynarrowing the openings. Also, third step 170 may form arterial portionsoriented a first direction, whereas fifth step 196 may form arterialportions oriented in a second direction. Following transfer steps 206,208, the knitting machine knits optional courses 210-216 and executesadditional transfer steps 218, 220 to further narrow the opening. Inother embodiments having smaller openings, courses 210-216 and transfers218, 220 may not be necessary. Likewise, in other embodiments havinglarger openings, fifth step 196 may include additional courses andtransfers. Following first through fifth steps 160, 164, 170, 192, and196, the knitting machine will have knitted a knit component withintersecting portions that are interlooped with tensile material, one ormore complete openings spanned by floats of the tensile material, andone or more arterial portions.

Although the foregoing knitting sequence describes five steps for thesake of comprehensive description, fewer steps may be necessary to forma tensile structure. For example, a first step may involve forming awidening part of an opening, arterial portions, and intersectingportions (as in third step 170 discussed above). A second step mayinvolve knitting a course of tensile material, including at least onestitch and a float that spans the opening, and continuing to formintersecting portions on either side of the float that may be integrallyknitted with the tensile material (as described in fourth step 192above). A third step may involve forming a narrowing part of an openingand additional arterial portions (as in fifth step 196 discussed above).

While various embodiments of the present disclosure have been described,the present disclosure is not to be restricted except in light of theattached claims and their equivalents. Rather, the embodiments discussedwere chosen and described to provide the best illustration of theprinciples of the present disclosure and its practical application tothereby enable one of ordinary skill in the art to utilize the presentdisclosure in various forms and with various modifications as are suitedto the particular use contemplated. It is intended and will beappreciated that embodiments may be variously combined or separatedwithout departing from the present disclosure and all exemplary featuresdescribed herein are applicable to all aspects of the present disclosuredescribed herein. Moreover, the advantages described herein are notnecessarily the only advantages of the present disclosure and it is notnecessarily expected that every embodiment of the present disclosurewill achieve all of the advantages described.

The invention claimed is:
 1. A knitting method, comprising: knitting afirst course of a multi-bed knit structure on a first needle bed and asecond needle bed; transferring a first plurality of stitches of thefirst course of the multi-bed knit structure to different needles,wherein the transferring of the first plurality of stitches widens afirst part of an opening in the multi-bed knit structure; knitting acourse of tensile material, including at least one stitch thatinterloops with the multi-bed knit structure and a float that spans theopening; knitting a second course of the multi-bed knit structure on thefirst and second needle beds; and transferring a second plurality ofstitches of the second course of the multi-bed knit structure todifferent needles, wherein the transferring of the second plurality ofstitches narrows a second part of the opening.
 2. The knitting method ofclaim 1, wherein the float has a float length of at least three needles.3. The knitting method of claim 1, wherein the multi-bed knit structurehas a tubular knit structure.
 4. The knitting method of claim 1, whereinthe course of tensile material has a diameter of at least 0.8 mm and atensile strength of at least 25 kg-f.
 5. The knitting method of claim 1,wherein the opening has a shape consisting of a triangle, a square, arectangle, a pentagon, an ellipse, or a circle.
 6. The knitting methodof claim 1, wherein the first needle bed and the second needle bed arepart of a weft knitting machine.
 7. The knitting method of claim 1,wherein transferring the first plurality of stitches also forms orlengthens first arterial portions of the multi-bed knit structure aroundthe first part of the opening.
 8. The knitting method of claim 7,wherein the first arterial portions are oriented in a first directionand wherein transferring the second plurality of stitches causes secondarterial portions of the multi-bed knit structure around the second partof the opening to be oriented in a second direction.
 9. A knittingmethod, comprising: knitting a first course of a multi-bed knitstructure on a first needle bed and a second needle bed, wherein themulti-bed knit structure has a tubular knit structure; transferring afirst plurality of stitches of the first course of the multi-bed knitstructure to different needles, wherein the transferring of the firstplurality of stitches widens a first part of an opening in the multi-bedknit structure; knitting a course of tensile material, including atleast one stitch that interloops with the multi-bed knit structure and afloat that spans the opening, wherein the float has a float length of atleast three needles; knitting a second course of the multi-bed knitstructure on the first and second needle beds; and transferring a secondplurality of stitches of the second course of the multi-bed knitstructure to different needles, wherein the transferring of the secondplurality of stitches narrows a second part of the opening.
 10. Theknitting method of claim 9, wherein the course of tensile material has adiameter of at least 0.8 mm and a tensile strength of at least 25 kg-f.11. The knitting method of claim 9, wherein the opening has a shapeconsisting of a triangle, a square, a rectangle, a pentagon, an ellipse,or a circle.
 12. The knitting method of claim 9, wherein the firstneedle bed and the second needle bed are part of a weft knittingmachine.
 13. The knitting method of claim 9, wherein transferring thefirst plurality of stitches also forms or lengthens first arterialportions of the multi-bed knit structure around the first part of theopening.
 14. The knitting method of claim 13, wherein the first arterialportions are oriented in a first direction and wherein transferring thesecond plurality of stitches causes second arterial portions of themulti-bed knit structure around the second part of the opening to beoriented in a second direction.
 15. A knitting method, comprising:knitting a first course of a multi-bed knit structure on a first needlebed and a second needle bed of a weft knitting machine; transferring afirst plurality of stitches of the first course of the multi-bed knitstructure to different needles, wherein the transferring of the firstplurality of stitches widens a first part of an opening in the multi-bedknit structure and forms or lengthens first arterial portions of themulti-bed knit structure around the first part of the opening; knittinga course of tensile material, including at least one stitch thatinterloops with the multi-bed knit structure and a float that spans theopening; knitting a second course of the multi-bed knit structure on thefirst and second needle beds; and transferring a second plurality ofstitches of the second course of the multi-bed knit structure todifferent needles, wherein the transferring of the second plurality ofstitches narrows a second part of the opening.
 16. The knitting methodof claim 15, wherein the multi-bed knit structure has a tubular knitstructure.
 17. The knitting method of claim 15, wherein the float has afloat length of at least three needles.
 18. The knitting method of claim15, wherein the course of tensile material has a diameter of at least0.8 mm and a tensile strength of at least 25 kg-f.
 19. The knittingmethod of claim 15, wherein the opening has a shape consisting of atriangle, a square, a rectangle, a pentagon, an ellipse, or a circle.20. The knitting method of claim 15, wherein the first arterial portionsare oriented in a first direction and wherein transferring the secondplurality of stitches causes second arterial portions of the multi-bedknit structure around the second part of the opening to be oriented in asecond direction.